Total Productive Maintenance Certification

Overall Equipment Effectiveness Standard

Total Productive Maintenance (TPM) is the process of preventing premature machine deterioration by identifying issues or problems early on and immediately finding applicable means to solve it. Its main objective is to maintain the equipment or plant in topmost condition without disrupting the efficient flow of daily production.  TPM ensures productivity by reducing wasteful usage of resources.

In Overall Equipment Effectiveness Standard wherein TPM is included, employees are constantly encouraged to imbibe a business culture that stimulates awareness and cooperative nature. It also requires a systematic and standardized approach to limit losses or damages. All departments involved are also encouraged to take on a reactive to predictive mindset for a maximized organizational output.

employee testing machine for equipment maintenance

TPM Total Productive Maintenance

TPM aims to achieve 3 goals: Zero Equipment Unplanned Failures, Zero Product Defects and Zero Accidents. By comparing the results of the potential performance and the actual performance (Gap Analysis), the maintenance team subsequently sets out to determine where possible deterioration occurred (if there are any) during the Initial Cleaning.

Many companies encounter problems in implementing TPM due to 2 reasons: 1) lack of knowledge and appropriate skills, and 2) shortage in time, resources and people.  Most books that discuss TPM are more theoretical than practical-based.  Information about proper implementation are scarce. Generally, the Overall Equipment Effectiveness Standard demands full participation from all the units of the company. Usually, it takes three to five years before improvements and positive results are felt. The majority of this period is allocated for the training of the operators wherein they restore the equipment to its original state and gradually improve it.

There are 8 Pillars of Activity involved in Overall Equipment Effectiveness Standard’s TPM:

  1. Focused improvement (Kobetsu Kaizen) –This is the continuous application of steady improvement on each step.
  2. Planned Maintenance –This focuses on the reduction of machine breakdowns and increased equipment availability.
  3. Initial Control – This aims to establish a dependable system that would enable the launching of new products and equipment within a minimum run-up time.
  4. Education & Training –The process of preparing and forming autonomous workers equipped with sufficient knowledge and appropriate skills to deliver productive maintenance.
  5.  Maintenance (Jishu Hozen) –The ability to maintain equipment independently.  There 7 steps included in Jishu Hozen.
  6. Quality Maintenance (Hinshitsu Hozen) –This is where excellent machine conditions are prioritized and occurrence of Zero Defectis sustained.
  7. Office TPM – Targets an efficient and functional office that makes no room for losses.
  8. Safety, Hygiene & Environment (SHE) – This aims to preserve a secure and healthy working environment where accidents don’t happen, hazardous areas are eliminated and activities are not interrupted.

QSE TPM Certification

The success of TPM can be measured by a fixed set of performance metrics that coincide with Overall Equipment Effectiveness (OEE). TPM can be achieved if the management knows, follows and applies effectively its philosophy. Training of all employees should be provided as well and formation of autonomous maintaining workers established. Generally, TPM takes 8 years to implement. QSE Consultants, a consultancy based in Atlanta, GA, offers assistance in successfully obtaining TPM Certification. They have a way to reduce time for sustainable results to 3 years with their disciplined approach. Call them at 770-518-9967 or visit Quality Systems Enhancement website today.

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